ENGINE. THESE HARDWARE ITEMS ARE NOT DESIGNED TO SUPPORT

Installation/Initial Startup and Engine Operation

ENGINE. THESE HARDWARE ITEMS ARE NOT DESIGNED TO SUPPORT

LOADS OTHER THAN THOSE ASSO-CIATED WITH ENGINE OPERATION 7-3 INSTALLATION

If not already installed in the package, the engine should be installed according to the packager's requirements and specifications.

For specific details on engine installation pro-cedures and tools, refer to work package (WP) 300 00, WP 301 00, WP 302 00, WP 303 00, and WP 001 00 as well as the packager's manual.

7-3.1 Site Information

Refer to the packager's manuals and drawings for installation design details.

7-3.2 Installation Procedure NOTE

• Use new preformed packings, seals, or gaskets at all connections where they are required.

• Refer to Chapter 6 and to the appro-priate packager’s manual for mount-ing points, interface locations, and component weights.

a. Install and align engine per packager's instructions.

b. Install starter onto accessory gearbox and configure the engine as required by the site and packager's instructions.

c. Install ignition leads per WP 103 00.

7-3.3 Equipment Protection

The engine is provided with covers that protect various operational interfaces during shipping, handling, installation, and maintenance activ-ity. These covers are provided and used to pro-tect the engine from potential FOD (foreign object damage) caused by handling and objects such as dirt, weld beads, tools, rags, nuts, and bolts.

7-3.3.1 Inlet Cover

The engine is shipped with an inlet cover that should only be removed when the engine is installed in the package. This cover should be retained by the operator and installed for engine protection any time the inlet connection is broken.

7-3.3.2 Exhaust Cover

The engine is shipped with an exhaust cover which should be left in place until the engine is mated to its interface.

Similar to the inlet cover, this cover should also be retained by the operator and installed any time the engine is disconnected.

7-3.3.3 Electrical, Fluid, and System Interface Covers

The engine is shipped with protective covers over all electrical, fluid, and system interfaces.

These covers are in place to prevent handling damage (threads, pins, etc.) and fluid or sys-tem piping contamination.

A supply of these covers should be maintained by the operator for use during maintenance activities that require electrical leads, fluid piping, or system piping to be disconnected.

7-3.4 Engine Protection

The LM2500

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SAC is a reliable, durable engine designed to operate in an industrial atmosphere for extended periods of time. How-ever, the operator needs to follow certain basic procedures in order to enhance the engine's operational capability.

7-3.4.1 Lubricating Oil Requirements Lubricating oil is used to lubricate bearings, gears, and some splines. Additionally, lube oil is used in the variable-geometry control actua-tion system. The oil must be temperature-con-trolled and kept clean per the following requirements in order to adequately perform its function.

a. The requirements for gas turbine/gas gen-erator lubricating oil are provided in Appendix A7.

b. Minimum temperature at start is 20°F (-6.7°C) for type II (MIL-L-23699) oil and -20°F (-28.9°C) for MIL-L-7808.

c. Minimum allowable temperature for oper-ation at idle or above is 90°F (32.2°C).

d. Normal supply temperature should be maintained between 140 to 160°F (59.9 to 71.1°C).

e. Minimum supply pressure above 4,500 rpm or idle is 8 - 15 psig (55.2 - 103.4 kPa gage). Above 8,000 rpm, the supply pres-sure is > 15 psig (103.4 kPa gage).

f. Mixing of different types (Type I versus Type II) of oils is not allowed. Mixing of oil brands of the same type is acceptable. Top-ping off when changing oil brands of the same type is the preferred method, but indiscriminate changing is not recom-mended.

CAUTION

FAILURE TO PROPERLY MAINTAIN A CLEAN LUBE SYSTEM COULD

RESULT IN PREMATURE FAILURE OF THE GT OR COMPONENTS.

g. Before the initial motoring and start of an engine in a new installation or following work on the lube system, the lube oil con-ditioning and storage system and all of the various circuits should be flushed to ensure cleanliness.

CAUTION

FOLLOWING THIS FLUSHING, THE SYSTEM FILTER ELEMENTS SHOULD BE REMOVED OR REPLACED TO AVOID ENGINE CONTAMINATION.

h. In the event of a failure during site opera-tion that involves the engine lube system, the complete system should be discon-nected, drained, and cleaned as described in the preceding step. This procedure should be followed whether the engine is removed and replaced or repaired on-site.

i. Engine oil should be filtered to 10 microns, nominal.

7-3.4.1.1 Lube Oil Pressure Corrections For Industrial LM2500

+

SAC Gas Turbines and Gas Genera-tors

Tables 7-1 through 7-4 and Figures 7-1 through 7-4 provide corrections and limits for lube supply pressure.

NOTE

• There can be significant site-to-site variation in typical lube system parameters based on variations in package designs, lube filters, and site engine operating profiles. A signifi-cant rise in lube scavenge temperature, or scavenge filter ΔP, can occur without reach-ing the recommended alarm or shutdown limits. It is possible for substantial secondary damage to occur in the time following a sig-nificant increase in scavenge temperature or filter ΔP prior to reaching the

alarm/shutdown limits.

• GE recommends that operators establish baseline readings for:

1. Lube scavenge temperatures for all engine sumps and the gearbox

7-5 2. Lube scavenge filter Δ pressure (clean

filter at max power and normal tempera-ture conditions)

• GE recommends that operators set new lube scavenge temperature and scavenge filter ΔP control limits for alarm and automatic shut-down based on increases in temperature or filter ΔP relative to the established baseline.

7-3.4.1.2 Lube Supply Pressure at Pres-sure Tap vs. Gas Generator/Gas Turbine Speed

Figures 7-5 (Sheet 1 of 4) through 7-5 (Sheet 4 of 4) provide nominal lube supply pressures at pressure tap vs. gas generator (GG)/GT speed and lube supply temperature for SAC models.

7-3.4.2 Air

Maximum airflow through the LM2500

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SAC engine is approximately 185 lb/sec (83.9 kg/sec) and is filtered by the inlet system to meet the following requirements:

• 95 percent of the time: must not contain solid particles exceeding

0.004 grains/1,000 ft³ (0.0003 g/28.32 m³)

• 5 percent of the time: must not contain solid particles exceeding 0.04 grains/1,000 ft³ (0.003 g/28.32 m³)

• When operating in a marine environment, sodium (from air or water) entering the engine should not exceed 0.00045 parts/

million (ppm) average, or 0.003 ppm maxi-mum

• The maximum allowable liquid water con-tent in the inlet air is 0.5 percent of the inlet airflow weight at inlet air tempera-tures of 42°F (5.6°C) and above. Below 42°F (5.6°C), no liquid water content is allowed 7-3.4.3 Gas Fuel

Gas fuel should be what is known in industry as dry gas. That is, the gasoline vapor in 1,000 ft³ (28.3 m³) of gas at standard conditions (60°F and 30 in. Hg abs [15.5°C and 764 mm Hg]) should not exceed 0.1 gal (0.37 l) of liquid.

Liquid hydrocarbons in gas fuel can cause surges in operation or engine damage. There-fore, gas fuel mixtures must be maintained at temperatures 50°F (27.7°C) above their dew-point at the engine fuel manifold inlet. The temperature of the gas fuel should not exceed 300°F (148.8°C) at the gas fuel manifold inlet.

The requirements for natural gas are provided in Appendix A1.

7-3.4.3.1 Liquid Fuel

The requirements for liquid fuel are provided in Appendix A4. The fuel shall be filtered to 20 microns absolute.

7-3.4.4 NOx Suppression

The requirements for water or steam injection for NOx suppression are provided in

Appendices A5 and A6.

Recommended

Table 7-1. Lube Oil Pressure Correction for Industrial LM2500

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SAC Gas Turbines with 6-Stage Power Turbine Using MIL-L-23699 Oil

NOTE

The following values are for corrections to 9,000 rpm NGG and 150°F (66°C) lube inlet temper-ature. Read oil pressure and temperature then algebraically add the pressure additive as indi-cated for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure limit is 45-55 psig (310-279 kPa).

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000

100 (38) - 7.74 - 8.93 -10.14 -11.35 -12.58 -13.81 -15.05 -16.31 -17.57 -18.85 -20.14

190 (88) +16.53 +15.80 +15.06 +14.31 +13.55 +12.77 +11.98 +11.18 +10.38 + 9.56 +8.74

200 (93) +17.57 +16.84 +16.10 +15.35 +14.60 +13.83 +13.06 +12.27 +11.46 +10.65 +9.83

210 (99) +18.40 +17.67 +16.93 +16.18 +15.42 +14.65 +13.88 +13.10 +12.31 +11.51 +10.71

220 (104) +19.08 +18.36 +17.64 +16.90 +16.16 +15.41 +14.65 +13.89 +13.12 +12.34 +11.55

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000

100 (38) -12.43 -22.74 -24.05 -25.37 -26.70 -28.04 -29.39 -30.76 -32.13 -33.50

110 (43) -16.30 -17.52 -18.74 -19.99 -21.27 -22.56 -23.86 -25.18 -26.51 -27.85

120 (49) -12.25 -13.39 -14.55 -15.17 -16.87 -18.05 -19.23 -20.42 -21.62 -22.83

130 (54) - 8.28 - 9.33 -10.38 -11.43 -12.49 -13.56 -14.64 -15.72 -16.81 -17.91

Example: Observed NGG 8700 RPM

Observed Oil Pressure 56 psig (386 kPa) Oil Temperature 130°F (54°C) Pressure Additive -4.14 psig (28.5 kPa)

Corrected Pressure 56 -4.14 = 51.86 psig (357.6 kPa)

7-7 Figure 7-1. Lube Oil Pressure Correction for Industrial LM2500

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SAC Gas Turbines

with 6-Stage Power Turbine Using MIL-L-23699 Oil

Table 7-2. Lube Oil Pressure Correction for Industrial LM2500

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SAC Gas Turbines Using MIL-L-7808 Oil

NOTE

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000

100 (38) - 4.69 - 5.36 - 6.58 - 7.54 - 8.51 - 9.50 -10.48 -11.46 -12.44 -13.44 -14.43

Gas Generator Speed (RPM)

°F (°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000

100 (38) -15.44 -16.46 -17.46 -18.47 -19.50 -20.52 -21.56 -22.60 -23.65 -24.70

110 (43) -11.53 -12.45 -13.37 -14.31 -15.24 -16.19 -17.14 -18.10 -19.07 -20.04

120 (49) - 8.00 - 8.87 - 9.74 -10.61 -11.50 -12.39 -13.28 -14.18 -15.08 -15.99

Example: Observed NGG 8600 RPM

Observed Oil Pressure 40 psig (276 kPa) Oil Temperature 140°F (60°C) Pressure Additive +1.28 psig (8.8 kPa)

Corrected Pressure 40 +1.28 = 41.28 psig (284.6 kPa)

7-9 Figure 7-2. Lube Oil Pressure Correction for Industrial LM2500

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SAC Gas Turbines

Using MIL-L-7808 Oil

Table 7-3. Lube Oil Pressure Correction for Industrial LM2500

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SAC Gas Generators Using MIL-L-23699 Oil

NOTE

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000

100 (38) -10.52 -12.01 -13.52 -15.04 -16.58 -18.12 -19.68 -21.25 -22.84 -24.43 -26.04

110 (43) - 5.20 - 6.60 - 8.03 - 9.49 -10.98 -12.48 -14.00 -15.53 -17.07 -18.59 -20.10

190 (88) +18.85 +17.84 +16.83 +15.82 +14.79 +13.74 +12.69 +11.62 +10.55 + 9.47 + 8.37

200 (93) +19.85 +18.87 +17.88 +16.88 +15.88 +14.86 +13.83 +12.79 +11.74 +10.68 + 9.61

210 (99) +20.79 +19.83 +18.87 +17.89 +16.91 +15.91 +14.91 +13.89 +12.87 +11.83 +10.79

220 (104) +21.68 +20.75 +19.80 +18.85 +17.89 +16.91 +15.93 +14.94 +13.93 +12.92 +11.90

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000

100 (38) -27.67 -29.30 -30.95 -32.61 -34.28 -35.96 -37.66 -39.37 -41.10 -42.85

110 (43) -21.62 -23.15 -24.70 -26.25 -27.80 -29.38 -30.97 -32.57 -34.18 -35.80

120 (49) -15.95 -17.35 -18.73 -20.11 -21.51 -22.93 -24.35 -25.78 -27.22 -28.67

130 (54) -10.25 -11.52 -12.80 -14.10 -15.40 -16.72 -18.03 -19.36 -20.70 -22.05

140 (60) - 5.43 - 6.54 - 7.75 - 8.97 -10.19 -11.43 -12.67 -13.92 -15.18 -16.45

Example: Observed NGG 8700 RPM

Observed Oil Pressure 56 psig (386 kPa) Oil Temperature 130°F (54°C) Pressure Additive -5.24 psig (36.1 kPa)

Corrected Pressure 56 -5.24 = 50.76 psig (349.9 kPa)

7-11 Figure 7-3. Lube Oil Pressure Correction for Industrial LM2500

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SAC Gas Generator

Using MIL-L-23699 Oil

Table 7-4. Lube Oil Pressure Correction for Industrial LM2500

+

SAC Gas Generators Using MIL-L-7808 Oil

NOTE

Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C) 8000 8100 8200 8300 8400 8500 8600 8700 8800 8900 9000

100 (38) - 4.08 - 5.20 - 6.34 - 7.49 - 8.65 - 9.82 -10.99 -12.18 -13.37 -14.57 -15.78

Gas Generator Speed (RPM)

°F (°C) 9100 9200 9300 9400 9500 9600 9700 9800 9900 10000

100 (38) -16.99 -18.22 -19.45 -20.70 -21.95 -23.21 -24.49 -25.76 -27.50 -28.35

110 (43) -12.03 -13.18 -14.34 -15.51 -16.68 -17.86 -19.05 -20.25 -21.46 -22.67

120 (49) - 7.78 - 8.89 - 9.93 -11.07 -12.24 -13.41 -14.60 -15.79 -17.00 -18.21

Example: Observed NGG 8600 RPM

Observed Oil Pressure 40 psig (276 kPa) Oil Temperature 140°F (60°C) Pressure Additive +2.88 psig (19.9 kPa)

Corrected Pressure 40 +2.88 = 42.88 psig (295.6 kPa)

7-13 Figure 7-4. Lube Oil Pressure Correction for Industrial LM2500

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SAC Gas Generator

Using MIL-L-7808 Oil

Figure 7-5. LM2500

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SAC Gas Turbine with 6-Stage Power Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-7808 Oil

(Sheet 1 of 4)

7-15 Figure 7-5.LM2500

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SAC Gas Generator Lube Supply Pressure at Pressure Tap

vs Gas Generator Speed Using MIL-L-7808 Oil (Sheet 2 of 4)

Figure 7-5. LM2500

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SAC Gas Turbine with 6-Stage Power Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-23699 Oil

(Sheet 3 of 4)

7-17 Figure 7-5. LM2500

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SAC Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator

Speed Using MIL-L-23699 Oil (Sheet 4 of 4)

7-3.4.5 Adjustment of Engine High Pres-sure Recoup Cavity PresPres-sure Within Preferred Operating Range

NOTE

High pressure recoup should be checked at initial startup and periodically thereaf-ter. Refer to Chapter 11, Table 11-1, and WP 417 00.

Maintenance of engine high pressure (HP) recoup cavity pressure in the preferred operat-ing range is required to ensure No. 4B bearoperat-ing life. During initial buildup of engine, HP recoup cavity pressure was adjusted into the preferred operating range with the proper size metering spacers.

Periodic plotting of the HP recoup cavity pres-sure is required in service, because seal leak-age can change with operation of the engine and may cause HP recoup cavity pressure to fall outside the preferred operating range.

Refer to WP 417 00 for procedure.

7-3.4.6 Adjustment of Power Turbine (PT) Thrust Balance Cavity Pres-sure Within Preferred Operating Range (6-Stage PT Applications Only)

NOTE

PT thrust balance cavity pressure should be checked at initial startup and periodi-cally thereafter. Refer to Chapter 11, Table 11-1, and Volume II, WP 431 00.

Maintenance of PT thrust balance cavity pres-sure in the preferred operating range is required to ensure No. 7B bearing life. During initial buildup of engine, PT thrust balance cavity pressure was adjusted into the preferred operating range with the proper size orifice plate.

Periodic plotting of the PT thrust balance cav-ity pressure is required in service because seal leakage can change with the operation of the engine. This may cause PT thrust balance cav-ity pressure to fall outside the preferred oper-ating range. Refer to Volume II, WP 431 00, for procedure.

7-3.5 Initial Prestart Inspections The engine and package should undergo a thorough prestart inspection during installa-tion or after maintenance to ensure a trouble-free transition from installation to full opera-tion. This inspection will help to detect poten-tial installation problems. The following inspections should be performed during instal-lation of the engine in the enclosure:

a. Inspect the enclosure per the packager's instructions.

b. Perform an external inspection. Ensure that all connections are tight and that no binding or chafing is evident on flexible electrical cables, hoses, or tubes.

c Bonding straps are in place and secure.

d. Inspect the engine inlet area. Thoroughly inspect the inlet plenum for dirt and for-eign objects. Clean, vacuum, and/or wash the area as necessary.

e. Inspect the exhaust system for foreign objects.

f. Ensure that the lube system is properly serviced.

g. Inspect for leaks in fuel and lube oil lines.

h. Ensure CRF leakage ports, struts 7 and 10, are open (not capped)

i. Ensure T5.4 thermocouple system func-tions properly.

j. Ensure steam manifolds are aligned (if required).

7-19 k. Ensure steam HP recoup system is

installed (if required).

l. Ensure fire/alarm system is functional.

7-3.6 Initial Operational Checkout CAUTION

IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE ENGINE UNTIL A THOROUGH INVES-TIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOR-OUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE

STRESS BEING IMPOSED ON ENGINE COMPONENTS, WITH IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAIL-URE OF THE ENGINE.

The initial startup procedures described in this section should be followed after any engine installation, GG replacement, or major system or engine maintenance. The engine should be operated at various speed/load conditions in order to establish baseline performance for the specific installation. Refer to

paragraph 7-4.4.1c.

a. Perform initial prestart inspection, per paragraph 7-3.5.

b. Perform normal prestart checks, per paragraph 7-4.2.

c. Motor the engine for 2 minutes per the packager's instructions and per Motoring in paragraph 7-4.3. During motoring, check for the following:

• Oil pressure indication

• Lube oil leaks

• Unusual noise during coastdown d. Perform false start as follows:

1. With ignition leads disconnected and fuel shutoff valves closed, make auto-matic start of GG per packager’s manual.

2. GG should go through normal start cycle and then abort because of lack of flame/ignition.

e. Perform prestart as follows:

1. With ignition system disabled, but with fuel shutoff valve open and gov-erning system operating, make auto-matic start of GG per packager’s manual.

2. GG should accelerate to applicable light-off speed. Fuel valve should open and fuel manifold pressure should be verified. Start will then abort because of lack of flame/ igni-tion.

3. Allow GG to coast to stop; then motor it to purge any remaining fuel from GG or drain liquid fuel from mani-folds (if liquid fuel was used). Con-tinue to motor for a minimum 60 seconds to purge fuel from GG. Con-sult packager’s manual for necessary prestart purge time.

f. Perform the following ignition system functional check:

WARNING

• IGNITION SYSTEM SHALL BE INOPERATIVE FOR AT LEAST 2 MINUTES BEFORE DISCON-NECTING IGNITION LEADS.

IGNITION SYSTEM COULD BE

In document Gek105054 LM2500 Plus O&M Manual (Page 157-173)